Core stranding of electric vehicle high-voltage cables

As we all know, in the high-voltage cables used in new energy vehicles, the layers of insulation layers of conductors are referred to as core wires, which are twisted into a single core with a specified laying distance and twisting direction, and wrapped with a layer of tape at the same time. . The so-called core, the twisted product of the core is called cable, which is one of the important processes in the production of stranded multi-core cables. The process of combining several insulated cores or units into a cable core is called core stranding.

With the rapid development of society and the continuous progress of science and technology, there are more and more varieties of wires and cables. From the current point of view, a variety of specifications and models have been counted, and each specification and model is suitable for different product types. According to the research and development of each enterprise, the corresponding manufacturing process, structural characteristics, functional requirements, product use, etc. Provide high-quality products for today's new energy wiring harness market. The finished cable must ensure the stability of the wire structure, be easy to process, increase the flexibility of the wire, and meet the requirements of electrical characteristics and appearance.

The cores are twisted, single twisted, twisted twisted, concentric twisted, coincident twisted, barrel twisted. The wire is twisted once for each turn of the stranding machine arm to form a pitch called: single twist arm. Each turn of the wire is twisted twice to form two pitches called: twisted pair. That is to say, with one or a bundle of wires as the core, according to the arrangement of layers, the direction of each layer is opposite. Stranding cannot be completed at one time. These conductors or core wires must be grouped and twisted into small strands, and then the small strands are twisted together in the form of bundles or layers to form a composite stranded wire called: composite stranded wire. It is the best structure to use multi-strand wire stranded wire as the wire core. This structure can not only greatly increase the flexibility of the cable, but also make the curvature not concentrated in one place, but distributed in each wire. On the other hand, the smaller the diameter of each wire, the smaller the bending stress generated when bending, so plastic deformation will not occur under the allowable bending radius, so that the insulation layer of the cable will not be damaged. At the same time, when bending, each wire can slip, and the layers are twisted in opposite directions, so that the tension and pressure on the inside and outside of the entire conductor are decomposed.

In general, if a single wire is used, it is not easy to bend and has poor flexibility, which brings difficulties to production, transportation, installation, laying and use; secondly, due to the large cross-section of a single wire, the eddy current loss is large, which affects the transmission effect.

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